Tunnel kiln car top



June 25, 1963 H. R. HERRON 3,094,759

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June 25, 1963 H, RHERRON 3,094,759

TUNNEL KILN CAR TOP Filed April 5, 1962 2 Sheets-Sheet 2 @T raf .5715.

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This invention relates to tunnel kiln cars, and more particularly to the refractory tops with .which they are provided.

This application is a continuation-in-part of my copending application, Serial No. 12,706, filed March 4, 1960, for Tunnel Kiln Car rfop, which has been abandoned in favor of the present application.

It is customary to provide a tunnel kiln car with a flat refractory top that supports a layer of sand, on which the articles that are to be tired :are set. Although a monolit-hic top would be ide-al in some respects, it is not practical in most cases for several reasons. It is therefore customary to form the top from a number of tiles. Tiles are cheaper and easier to handle, and if any of them break, it is a simple matter to replace them. However, when a top is formed from a large number of tiles, there necessarily is a large number of joints between them. It is conventional to place silica sand or quartz over the upper surface of the car top to prevent sticking between items being fired in the kiln :and the car top; and this sand has had a tendency to sift down the joints between tiles. The sand deposits tended to lbuild up and the joints became packed, so that when the oars were passed through the kiln, because of differences in thermal expansion between the quartz or sand and the refractory tiles, there was buckling of the tiles, car top failure, and in some instances spreading of the top suiiicient to cause contact with internal kiln walls resulting in wrecks inside the kiln. Also, since the top also becomes uneven in the process, breakage of ware supported by it may occur. The mechanical handling of cars and the ware on them are other causes of oar top destruction. Any severe bumping of the cars together or ramrning by lift trucks will usually knock the car top out of alignment `and soon require it to be rebuilt.

The monolithic type tops above referred to seemed an answer to the problem of sand build up in joints. But monolithic tops have not been successful, because the temperatures involved in tunnel kiln used for tiring refractories is much greater than presently available, eastable or monolithic material can successfully withstand Without failure due to cracking.

It is among the objects of this invention to provide a tunnel kiln car top which is made from a large number of small tiles, but in which the tiles are interlocked together; and interlocked in such a m'anner as to prevent silica sand build up in joints.

The invention -is illustrated in the accompnaying drawings, in which:

FTG. 1 is a side view of a kiln car provided with my top;

FiG. 2 is an enlarged plan view of the top;

FIG. 3 is [an end view of the top alone; Iand FIGS. 4, 5 and 6 are plan views of other patterns in which the same tile shapes as shown in FIG. 2 can be arranged.

Referring to FIG. l of the drawings, a conventional kiln car l supports suitable cored refractory blocks 2, on which a liat top 3 is mounted. The top consists of la number of interlocking tiles. As shown in FIG. 2, the tiles are made in several dierent shapes, a maximum of four shapes being required, with tiles of one shape made as both rights land lefts. For the purpose of this description, tiles 4 will be called the first shape, which is like 3,094,759 Patented June 25, 1963 ice a horizontal T that has a stem 5 crossed at one end by a bar 6 that projects from opposite sides of the stem. The second 'shape forming tiles 7, is produced by integrally joining two tiles 4 of the iirst shape stem-to-ste-m so that their cross bars :are -at opposite ends of the tile. In actual practice, tile 7 would be considered the basic shape, because the other yshapes can be cut from it. Tiles 8 have the third shape, which is the same as the first sh-ape, except that one end of the cross bar has been omitted. These tiles are made in rights and lefts. The fourth or last shape, Afor tiles 9, is like two tiles 8 (right and left) of the third shape joined stem to stem with their cross bars at opposite ends of the tile where they project from only one and the same side of the stem. The stem side 10 of each end of all cross bars forms Ian acute `angle with the adjoining stern. Therefore, the space between the cross bars of each tile 7 and 9 lforms at the side of the tile a dovetail notch ll.

The tiles are arranged in parallel rows, preferably eX- tending crosswise of the car. The two outer rows, which are at the front and back of the car, are for-med entirely of tiles 9 because they have flat sides extending from end to end and can therefore form fiat ends for the top. Their notched sides face inwardly. The row of tiles eng-aging each outer row is composed mainly of tiles 7 arranged bar to bar, with their stems in alignment. These tiles are staggered relative to those in the outer rows, so that the joints between tiles 7 are opposite the centers of tiles 9. Since the width of each notch l1 is about a sixteenth of an inch greater than twice the width of a tile cross bar, each notch in tiles 9 can receive and retain the ends of a pair of cross bars on two adjoining tiles 7 beside it. This sixteenth inch dierence in wdith is repeated across the top in all the notches 11 and is maintained during all temperature variations because all the tiles are fabricated of the same material and thus have an identical coefcient of thermal expansion. Likewise, the cross bars on tiles 9 are retained in the notches in the sides of tiles 7 beside them. Since tiles 7 extend only half way across the two end tiles 9 in each outer row, the space remaining is filled 'by two tiles 4 of the rst shape, which therefore form the ends of the second row and make it the `same length `as the outer row. It will be seen that all of the tiles in the two rows at each end of the car -are interlocked by the cross bar ends and the notches in two directions, lengthwise and crosswise of the car.

The rest of the rows of tiles could be formed solely of tiles 4 and 7 linterlocking in the same way as those just described. In that case, every other row would be composed entirely of tiles 7. However, in order to permit the ear top to be removed from the car mechanically, it is desirable to make the top divisible into sections small enough to be handled. For that purpose, the top may be divided into completely separate -front `and back half sections. To do that, the top is made lfrom an even number of rows of tiles, and the two center yrows may he formed of tiles 9 placed back to back. Since half of the top may still be too large to remove as a unit, it is desirable to divide the top into quarters before it is removed. rlihis can be done by rst removing the middle tile 9 from each outer row, but as it would be difficult to lift out the middle tile 7 in the center row of each half section of the top, it is preferred to use two tiles 4 in place of that middle tile 7. The two tiles 4 `are placed stern to stern as shown. For the same reason, two tiles 8 are used instead of the center tile in each center row of tiles 9.

Therefore, the car top not only has a joint extending straight across the car between the two center rows, but also another straight joint extending lengthwise of the car across the centers of the two half sections of the top from the front to the rear row. In use, the two outer rows of tiles hold the halves of the half sections of the top togethcr, and the pressure of the ends of the tops against one another as a line of cars is pushed through a kiln will hold the half sections together. By merely removing the middle tile 9 from each outer row, a top is divided into four quarter sections.

The bottom of each tile preferably is provided centerly of its stem with a downwardly opening recess 13 that extends throughout the length of the tile as illustrated in FIGS. l and 3. When the tiles are laid in rows, these recesses form a continuous passage from one end of the Iow to the other. Because of the one sixteenth inch difference in width between the notches 11 and a pair of tile cross bars, the joints between tiles are in open communication with these continuous passages, and sand is thus free to sift downwardly into them. The passages serve three functions. They help to cool the tiles, they provide openings for receiving vacuum lances to clean out sand that sifts down between the tiles, thereby preventing sand -buildup and related diliculties, and they also provide openings for receiving long parallel fingers on a device for lifting a quarter section of the top as a unit. The tiles may likewise be provided with similar recesses 14 in the lower outer corners of each cross bar.

In the modifications shown in FIGS. 4, and 6, threev different patterns or arrangements of tiles in a kiln car top are shown. The tiles have the same shapes as those shown in FIG. 2. It will be understood that as many tiles as desired can be connected together to form a oar top of any desired size.

ln the embodiment shown in FIG. 4, the arrangement is such that each outer row of tiles contains a tile 8 at one end in addition to the tiles 9 that make up the rest of those rows. As a result, it is necessary that one end of each intermediate row of tiles 7 contain a tile 4 to make all of the rows the same length. Because the rows are staggered, tiles 4 will fall at opposite ends of adjoining rows. This pattern can be used where a kiln car is not wide enough to support a top in which the outer rows are made up entirely of tiles 9.

In FIG. 5, tiles 8 are located at all four corners of the car top, with the result that the rows immediately adjoining the outer rows are composed entirely of tiles 7. The center row has tiles 4 at `both ends to make it come out the same length as the other rows.

In the moditication shown in FIG. 6, the outer rows are composed entirely of tiles 9, the center row is formed only of tiles 7, and the remaining two rows are each composed of tiles 7 with tiles 4 at both ends. This arrangement is similar to a half-section of the top shown in FIG. 2, but it does not contain any tiles 8 of the third shape, and the middle tile in the center row is not formed from two tiles 4 as it is in FIG. 2.

According to the provisions of the patent statutes, I have explained the principle of my invention and have illustrated and described what I now consider to represent its best embodiment. However, I desire to have it understood that, Within the scope of the appended claims, the invention may be practiced otherwise than as specically illustrated and described.

I claim:

1. A tunnel kiln car top comprising a plurality of interlocking tiles disposed in parallel rows, all said tiles fabricated of the same refractory material, said tiles including three different shapes, the iirst shape -being like a horizontal T having a stem and across bar, the second shape being like two of said first shape joined stem to stem to locate the cross bars at opposite ends of the tile, the last shape being like the second shape but with the ends of both cross bars omitted at one side of the stem, the Stem side of each end of the cross bars forming an acute angle with the adjoining stem, the tiles in each row being arranged bar to bar with their stems in alignment, tiles of said last shape being in the two outer rows, tiles of said first and second shapes being in only the intermediate -rows with said first shape only at row ends, and

the space between the cross bars of each tile of the second and last shapes forming at the side of the tile a dovetail notch receiving and retaining the ends of a pair of cross bars of two tiles in an adjoining row, said dovetail notch being wider than a said pair of cross bars, whereby the tiles are interlocked in two directions horizontally at right angles to each other, the bottom of each tile being provided centrally of its stem with a downwardly opening recess extending throughout the length of the tile, all of said recesses in each row being in alignment with one another and in open communication with some of the joints between tiles.

2. A tunnel kiln car top comprising a plurality of interlocking tiles disposed in parallel rows, all said tiles fabricated o the same refractory material, said tiles including three different shapes, the lirst shape being like a horizontal T having a stem and a cross bar, the second shape being like two of said rst shape join stem to stern to locate the cross bars at opposite ends of the tile, the last shape being like the second shape but with the ends of both cross bars omitted at one side of the stem, the stem side of each end of the cross bars forming an acute angle with the adjoining stem, the tiles in each row being arranged bar to bar with their stems in alignment, the two outer rows consisting of only tiles of said last shape, said top including a plurality of alternate intermediate rows consisting of only tiles of said second shape with tiles of said first shape at the opposite ends of the same rows, and the space between the cross bars of each tile of the second and last shapes forming at the side of the tile a dovetail notch receiving and retaining the ends of a pair of cross bars of two tiles in an adjoining row, said dovetail notch being wider than a said pair of cross bars, whereby the tiles are interlocked in two directions horizontally at right angles to each other, the bottom of each tile being provided centrally of its stem with a downwardly opening recess extending throughout the length of the tile, all of said recesses in each row being in alignment with one another and in open communication with some of the joints between tiles.

`i. A tunnel kiln car top comprising a plurality of interlocking tiles disposed in parallel rows, all said tiles fabricated -of the same refractory material, said tiles consisting of four different shapes, the rst shape being like a horizontal T having a stem and a cross bar, the second shape being like two of said lirst shape being joined stem to stem to ilocate the cross bars at opposite ends of the tile, the third shape being like the iirst shape but with one end of the cross bar omitted, the last shape being like two of said third shape joined stem to stern to locate the cross bars at opposite ends of the tile and projecting from the same side of the stern, the Istem side of each end of the cross bars forming an acute angle with the adjoining stem, the tiles in each row being arranged bar to bar with their stems in alignment, tiles of said third and last shape being in the two outer rows with said third shape lonly at row ends, tiles of said iirst and second shapes being in only the intermediate rows with said irst shape only at row ends, and the space between the cross bars of each tile of the second and last shapes forming at the side of the tile a dovetail notch receiving and retaining the ends of a pair of cross bars of two tiles in an adjoining row, said dovetail notch beingi Wider than a said pair of cross bars, whereby the tiles Iare interlocked in two directions horizontally at right angles to each other, the bottom of each tile being provided centrally of its stem with a downwardly opening recess extending throughout the length of the tile, all of said recesses in each row being in alignment with one another and in open communication with some of the joints between tiles.

4. A tunnel kiln car top comprising a plurality of interlocking tiles disposed in parallel rows, `all said tiles fabricated of the same refractory material, said tiles consisting of four dilerent shapes, the trst shape being like a horizontal T having a stem and a cross bar, the second shape being ylike two of said first shape joined stem to stern to locate the cross bars at opposite ends of the tile, the third shape being like the iirst shape but with one end of the cross bar omitted, the last shape being like two of said third shape joined stern to stem to locate the cross bars `at opposite ends of the tile and projecting from the same side of the stem, the stern side of each end of the cross bars forming an acute angle with the -adjoining stem, the tiles lin each row being arranged bar to bar with their stems in alignment, the two outer rows consisting of `only tiles of said last shape with tiles of said third shape at the `opposite ends of the same rows, said top including a plurality of alternate intermediate rows consisting of only tiles of said second shape, and the space between the cross bars of each tile of the second land last shapes forming vat the side of the tile a dovetail notch receiving and retaining the ends of a pair of cross bars of two tiles in an adjoining row, said dovetail notch being wider than a said pair of cross bars, whereby the tiles are interlocked in two directions horizontally at right angles to each other, the bottom of each tile being provided centrally of its stem with a downwardly opening recess extending throughout the length of the tile, all of said recesses -in each row being in alignment with one another and in open communication with some of the joints between tiles.

5. A tunnel kiln car top comprising a plurality of interlocking tiles disposed in an even number of parallel rows, all said tiles fabricated of the same refractory material, said tiles consisting of four different shapes, the first shape being like a horizontal T having ya stem and a cross bar, the second shape being like two of said rst shape joined stem to stem to locate the cross bars at opposite ends of the tile, the third shape being like the irst shape but with one end of the cross bar omitted, the last shape being like two of said third shape joined stem to stem to locate the cross bars at opposite ends of the tile and projecting from the same side of the stem, the stem side of each end of the cross bars forming an acute angle with the adjoining stem, the tiles in each row lbeing arranged bar to bar with their stems in alignment, the two outer rows consisting of only tiles of said last shape, each of the two center rows consisting of `only tiles of said last shape with a pair `of tiles of said third shape disposed stern to stem at the middle of the row, each of alternate intermediate rows between the outer rows yand the center rows consisting of only tiles `of said second shape with tiles of said rst shape `at their opposite ends, each of the rows between said alternate rows consisting of tiles of said second shape with two tiles of said rst shape disposed stem to stem at its middle and the space between the cross bia-rs of each tile of the second and last shapes forming at the side of the tile a dovetail notch receiving and retaining the ends of a pair of cross bars of two tiles in an adjoining row, said dovetail notch being wider than a said pair of cross bars, whereby the tiles are interlocked -in two directions horizontally at right angles to each other, the bottom of each tile being provided centrally of its stem with a downwardly opening recess extending throughout the length of the tile, all of said recesses in each row being in alignment with one another and in open communication with some of the joints between tiles.

6. A tunnel kiln car top comprising a plurality of interlocking tiles disposed in parallel rows, yall said tiles fabricated of refractory materials having similar coe'icients of thermal expansion, said tiles including three diierent shapes, the iirst shape being like a horizontal T having a stem land a cross bar, the second shape being like two of said first shape joined stem to stem to locate the cross bars at opposite ends of the tile, the last shape being like the second shape but with the ends of both cross bars lomitted at one side of the stem, the stern side of each end of the cross bars forming an acute angle with the adjoining stem, the tiles in keach row being arranged bar -to bar with their stems in alignment, tiles of said last shape being in the two outer rows, tiles of said first and second shapes being in only the intermediate rows with said rst shape only at row ends, and the space between the cross bars lof each tile of the second and last shapes forming at the side of the tile a dovetail notch receiving and retaining the ends of a pair of cross bars of two ti-les in an adjoining row, said dovetail notch being wider than a said pair of cross bars, whereby the tiles lare interlocked in two directions horizontally at right angles to each other, the bottom of each tile being provided centrally of its stern with a downwardly opening recess extending throughout the length of the tile, all of said recesses in each row being in alignment with one another fand in open communication with some of the joints between tiles.

References Cited in the file of this patent UNITED STATES PATENTS 1,306,160 Zwenmann June 10, 1919 1,485,109 Beth et al. Feb. 26, 1924 1,587,210 Beecher et al. lune 1, 1926 2,099,149 Turnquist Nov. 16, 1937 2,104,307 Miller lan. 4, 1938 

1. A TUNNEL KILN CAR TOP COMPRISING A PLURALITY OF INTERLOCKING TILES DISPOSED IN PARALLEL ROWS, ALL SAID TILES FABRICATED OF THE SAME REFRACTORY MATERIAL, SAID TILES INCLUDING THREE DIFFERENT SHAPES, THE FIRST SHAPE BEING LIKE A HORIZONTAL T HAVING A STEM AND A CROSS BAR, THE SECOND SHAPE BEING LIKE TWO OF SAID FIRST SHAPE JOINED STEM TO STEM TO LOCATE THE CROSS BARS AT OPPOSITE ENDS OF THE TILE, THE LAST SHAPE BEING LIKE THE SECOND SHAPE BUT WITH THE ENDS OF BOTH CROSS BARS OMITTED AT ONE SIDE OF THE STEM, THE STEM SIDE OF EACH END OF THE CROSS BARS FORMING AN ACUTE ANGLE WITH THE ADJOINING STEM, THE TILES IN EACH ROW BEING ARRANGED BAR TO BAR WITH THEIR STEMS IN ALIGNMENT, TILES OF SAID LAST SHAPE BEING IN THE TWO OUTER ROWS, TILES OF SAID FIRST AND SECOND SHAPES BEING IN ONLY THE INTERMEDIATE ROWS WITH SAID FIRST SHAPE ONLY AT ROW ENDS, AND THE SPACE BETWEEN THE CROSS BARS OF EACH TILE FO THE SECOND AND LAST SHAPES FORMING AT THE SIDE OF THE TILE A DOVETAIL NOTCH RECEIVING AND RETAINING THE ENDS OF A PAIR OF CROSS BARS OF TWO TILES IN AN ADJOINING ROW, SAID DOVETAIL NOTCH BEING WIDER THAN A SAID PAIR OF CROSS BARS, WHEREBY THE TILES ARE INTERLOCKED IN TWO DIRECTIONS HORIZONTALLY AT RIGHT ANGLES TO EACH OTHER, THE BOTTOM OF EACH TILE BEING PROVIDED CENTRALLY OF ITS STEM WITH A DOWNWARDLY OPENING RECESS EXTENDING THROUGHOUT THE LENGTH OF THE TILE, ALL OF SAID RECESSES IN EACH ROW BEING IN ALIGNMENT WITH ONE ANOTHER AND IN OPEN COMMUNICATION WITH SOME OF THE JOINTS BETWEEN TILES. 